Abstract
The wire electrical discharge machining process (WEDM) is high demand and influenced by various input process parameters namely pulse duration, voltage, wire diameters and wire material. In this research a smart material made of TiNiCo alloy is investigated to study the machinability using WEDM process. The pulse duration and servo voltage varied to perform the experiments on Ti50Ni49Co1 Ti50Ni45Co5 and Ti50Ni40Co10 smart materials for bone staple applications which was designed by ELCAM software and generated G-code for machining with same software. L-25 orthogonal array used for machining of selected alloys, which is created (L-25 orthogonal array) through Taguchi design of experiment. From the experiments analysis are made to study the amount of material removal and average roughness as response. Further machined areas are subjected to metallurgical characterizations techniques such as surface topography, X-ray diffraction, residual stress calculation and wear mechanism to discuss in details. Tensile residual stress were noticed at higher values of outputs while lower values of residual stress at lower values of outputs which is also confirm through microstructure and surface topography that smoother surface has been found at lower values of outputs. Moreover XRD analysis exhibits the oxide formation on the machined surface due to partial oxidation and vaporization of fused metal.